EP2334540B1 - Bonding with adhesive beads or plots - Google Patents
Bonding with adhesive beads or plots Download PDFInfo
- Publication number
- EP2334540B1 EP2334540B1 EP09809354.5A EP09809354A EP2334540B1 EP 2334540 B1 EP2334540 B1 EP 2334540B1 EP 09809354 A EP09809354 A EP 09809354A EP 2334540 B1 EP2334540 B1 EP 2334540B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- carrier
- adhesive
- cavity
- structural member
- inner walls
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 239000000853 adhesive Substances 0.000 title claims description 147
- 230000001070 adhesive effect Effects 0.000 title claims description 147
- 239000011324 bead Substances 0.000 title claims description 76
- 230000001681 protective effect Effects 0.000 claims description 20
- 238000000034 method Methods 0.000 claims description 13
- 239000012530 fluid Substances 0.000 claims description 10
- 239000004677 Nylon Substances 0.000 claims description 8
- 229920001778 nylon Polymers 0.000 claims description 8
- 229910052751 metal Inorganic materials 0.000 claims description 7
- 239000002184 metal Substances 0.000 claims description 7
- 239000000203 mixture Substances 0.000 claims description 7
- 238000003780 insertion Methods 0.000 claims description 6
- 230000037431 insertion Effects 0.000 claims description 6
- 239000004033 plastic Substances 0.000 claims description 6
- 229920003023 plastic Polymers 0.000 claims description 6
- 230000003014 reinforcing effect Effects 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 2
- 239000003822 epoxy resin Substances 0.000 claims description 2
- 229920000647 polyepoxide Polymers 0.000 claims description 2
- 229920000642 polymer Polymers 0.000 claims description 2
- 239000011368 organic material Substances 0.000 claims 2
- 239000011248 coating agent Substances 0.000 claims 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 claims 1
- 229920005992 thermoplastic resin Polymers 0.000 claims 1
- 238000013459 approach Methods 0.000 description 19
- 238000001723 curing Methods 0.000 description 13
- 239000006260 foam Substances 0.000 description 9
- 239000000463 material Substances 0.000 description 6
- 230000002787 reinforcement Effects 0.000 description 5
- 239000003566 sealing material Substances 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- 239000000356 contaminant Substances 0.000 description 3
- 239000000428 dust Substances 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- -1 moisture Substances 0.000 description 3
- 239000004848 polyfunctional curative Substances 0.000 description 3
- 238000004381 surface treatment Methods 0.000 description 3
- 240000005428 Pistacia lentiscus Species 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
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- 239000004814 polyurethane Substances 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- ZCYVEMRRCGMTRW-UHFFFAOYSA-N 7553-56-2 Chemical compound [I] ZCYVEMRRCGMTRW-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- KRVSOGSZCMJSLX-UHFFFAOYSA-L chromic acid Substances O[Cr](O)(=O)=O KRVSOGSZCMJSLX-UHFFFAOYSA-L 0.000 description 1
- 150000002118 epoxides Chemical class 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- AWJWCTOOIBYHON-UHFFFAOYSA-N furo[3,4-b]pyrazine-5,7-dione Chemical compound C1=CN=C2C(=O)OC(=O)C2=N1 AWJWCTOOIBYHON-UHFFFAOYSA-N 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 229910052740 iodine Inorganic materials 0.000 description 1
- 239000011630 iodine Substances 0.000 description 1
- 239000012948 isocyanate Substances 0.000 description 1
- 239000013521 mastic Substances 0.000 description 1
- 238000007591 painting process Methods 0.000 description 1
- 238000005554 pickling Methods 0.000 description 1
- 229920000768 polyamine Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001228 polyisocyanate Polymers 0.000 description 1
- 239000005056 polyisocyanate Substances 0.000 description 1
- 229920005862 polyol Polymers 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 238000007788 roughening Methods 0.000 description 1
- 238000005488 sandblasting Methods 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000007669 thermal treatment Methods 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
- 239000011345 viscous material Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
- B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
- B62D29/002—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material a foamable synthetic material or metal being added in situ
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/14—Layer or component removable to expose adhesive
- Y10T428/1452—Polymer derived only from ethylenically unsaturated monomer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/14—Layer or component removable to expose adhesive
- Y10T428/1471—Protective layer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24612—Composite web or sheet
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24843—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] with heat sealable or heat releasable adhesive layer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24917—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including metal layer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24926—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including ceramic, glass, porcelain or quartz layer
Definitions
- the present disclosure is directed toward methods and systems for providing structural reinforcement.
- bodies or housings with hollow cavities therein.
- various consumer appliances and vehicles may have hollow cavities formed between inner and outer panels of the bodies or housings, such as in pillars or within frame members.
- some structural members of automobile bodies include a variety of pillars, members, rails, beams, posts, etc. (collectively referred to as "cavities") connected by one or more nodes.
- Such hollow pillars, beams, etc. often assist in reducing the overall weight of the final product, as well as reducing material costs.
- these cavities often result in a structural member that lacks sufficient strength or energy-absorbing characteristics.
- Structural reinforcers often include a carrier with an expandable material configured to expand and mold to an inner surface of the structural member.
- the carrier portion is typically a molded component made from nylon, glass-reinforced nylon, metal, or some combination thereof, and is designed to be lightweight yet stiff.
- the carrier may also include a plurality of ribs configured to increase the carrier's response to specific stresses.
- the molded carrier structural reinforcers described above have drawbacks.
- expandable foam layers generally are relatively large, and provide only moderate strength increases, particularly with regard to shear and tensile stresses.
- the portions of the reinforcer which are foamable material lack the comparable strength of the molded carrier portion.
- such reinforcers generally require a large gap between the carrier and an interior wall of a cavity to be reinforced.
- the required gap between the molded carrier and the interior walls defining the cavity is generally a minimum of 6 - 10 mm. With a gap of this size, it is possible that the gap will not be properly sealed when the foam expands, due to conditions such as high assembly tolerances, variations in baking conditions, etc.
- the foam does not expand uniformly, it is possible that portions of the gap will remain unsealed, or that the carrier will not be properly secured within the cavity. Further, it is difficult to design a foaming structural reinforcer including one or more channels within the cavity, to allow fluid, such as e-coat fluid, to flow therethrough. Additionally, expandable foam reinforcers generally provide only moderate reinforcement with regard to shear and tensile loads.
- US 6 058 673 A discloses a reinforcement for hollow structural elements, with an I-shaped cross section.
- GB 2 375 328 A discloses a reinforcing element for hollow structural members, with an M-shaped or C-shaped cross section.
- WO 2006/091794 A1 discloses a bonded hybrid structure, in which a plastic component is bonded to a metal component to form a lightweight reinforced structure.
- the present disclosure is directed to systems and methods for providing structural reinforcement. More specifically, the disclosure is directed to structural reinforcers configured to be adhesively secured within a cavity.
- the structural reinforcer may include a carrier conforming generally in shape to one or more inner walls defining the cavity.
- An adhesive is placed on a reinforcer and / or a structural member. The adhesive may retain a substantially stable shape prior to insertion of the reinforcer within the structural member.
- the present disclosure allows a much closer fit between the carrier of the reinforcer and the inner walls defining a cavity within the structural member.
- the present disclosure also eliminates the need to use expandable foams or mastics as a sealer along with the adhesive.
- the present disclosure also simplifies the inclusion of channels between the reinforcer and the structure, for fluid flow, and allows simplified design for localized placement of adhesive. This may allow a reinforcer to be designed using less adhesive, leading to cost savings.
- a protective film may also be provided over some or all of the adhesive, and may protect the adhesive from dust, moisture, contaminants, or contact with other elements. This may, for example, allow for adhesive to be placed on a service part prior to the part leaving a factory, while preventing the adhesive curing prematurely.
- exemplary approaches described herein include a structural reinforcer having a carrier configured to provide reinforcement to a structural member.
- the structural member may be, for instance, a beam, a channel, a pillar, etc., within an appliance, a vehicle, such as an automobile, etc.
- the reinforcer is adhered to the structural member using an adhesive.
- the reinforcer may be made of metal, such as aluminum or steel, plastic, nylon, glass-reinforced nylon, a foam structure, an organic structure, or some combination thereof.
- the reinforcer is made of a thermoplastic material.
- the reinforcer may be made through extrusion, through injection molding, or through other suitable process.
- the reinforcer may include one or more ribs therein to provide localized strengthening, based on a particular application. At least a portion of the reinforcer may be designed to conform closely in shape to a portion of the structural member to which it is to be adhered.
- one or more outer faces of the carrier portion of the structural reinforcer may be configured to conform generally to one or more inner faces defining a cavity within the structural member.
- the gap between portions of the carrier, and one or more inner faces of the structural member to which the carrier is to be adhered between 4 mm and 0.5 mm.
- the size of the gap may be determined or designed based on application needs, production methods, etc. In one approach the gap may be designed to between about 2 mm and about 4 mm.
- An adhesive is used to secure the reinforcer to the structural member.
- the adhesive may be applied to the reinforcer, such as along an outer face of the carrier, and / or to the structural member, such as along one or more inner walls defining a cavity in the structural member.
- the adhesive may be applied prior to placement of the reinforcer proximate the structural member, which may position the carrier member within the cavity.
- the adhesive may cure while the carrier is positioned within the cavity, thereby adhering the structural reinforcer to the structural member.
- Adhesive may be applied as one or more adhesive beads, or plots, on one or more faces of the carrier, and / or on one or more inner faces of the structural member.
- the length, width, thickness, shape, cross-section, surface, quantity and placement of the adhesive beads or plots may vary as appropriate for any particular application, based on application parameters such as minimizing cost, maximizing strength, speeding assembly time, etc.
- beads may be applied as a continuous semicircular bead, a series of parallel lines, a series of contiguous plots, a series of round adhesive plots, a series of concentric circles, in a zigzag pattern, or according to any other design.
- the thickness of adhesive beads may be determined based on specific application needs. In one exemplary approach, the bead thickness is a minimum of about 150% of the width of the gap defined by the opposing surfaces which are mated by the adhesive.
- the adhesive employed may be any of a number of adhesives.
- the chosen adhesive may be substantially non-foaming. That is, the chosen adhesive may expand less than about 20% when curing. In one exemplary approach, the adhesive NEr, 10.01.2018 may expand less than about 5% when curing. In another exemplary approach, the adhesive is non-expandable.
- the chosen adhesive may have a viscosity that is high enough that the adhesive will retain its bead shape until the reinforcer is positioned within the structural member, yet low enough that the adhesive may be at least partially deformed or displaced upon insertion of the reinforcer within the structural member. In one approach the adhesive may have a paste-like consistency prior to curing, and / or may be tacky.
- the adhesive may act like a Bingham plastic, retaining a substantially stable shape prior to application of sufficient stress.
- the chosen adhesive may cure through exposure to air, atmospheric moisture, another chemical, heat, light, or according to any other appropriate curing method.
- the adhesive may be chosen such that the adhesive will cure when exposed to heat, such as during a baking or e-coat process.
- the adhesive may be, for example, a polymer composition including at least a resin and a hardener.
- the adhesive may be a polyurethane composition, a polyurethane and polyol isocyanate composition, an acrylate composition, an epoxide composition, etc.
- the adhesive may include an epoxy resin and hardener, such as a polyisocyanate or polyamine hardener, microencapsulated acrylic or methacrylate, etc.
- Suitable adhesives include those adhesives described in patent application serial number WO/2008/077944 .
- the adhesive may be extruded on the carrier and / or the structural member through an automated process, such as by a robot on an assembly line, or manually, such as by an operator using an extruder gun.
- the adhesive may be heated to assist in extrusion, or may be applied at ambient temperature.
- the adhesive may be provided to an assembly location in drums.
- the adhesive may be provided, for example, in the form of a paste, or a viscous material.
- a protective film may be applied over the adhesive, and may prevent the adhesive from curing prematurely, prevent dust or other contaminants from sticking to the adhesive, protect the adhesive from exposure to moisture or air, and / or ensure shelf life and adhesion properties.
- the protective film may be co-extruded with the adhesive, or may be applied on top of the extruded adhesive.
- the protective film may be a plastic, such as polyethylene.
- the protective film may be removed prior to, during, or after placing the structural reinforcer proximate the structural member.
- the protective film may be removed, for example, by peeling the protective film from the adhesive, by cutting the film from the adhesive, by the application of heat, chemicals, light, etc., or through other appropriate means.
- Figure 1 illustrates an exemplary reinforcer 100 having a base 110 and a carrier 120 connected thereto.
- the exemplary carrier portion 120 conforms generally in shape to a cavity 170 defined by one or more interior walls 180 of a structural member 160.
- the base 110 may include one or more faces that are substantially coplanar with one or more faces of structural member 160, and configured to butt against the structural member 160 to limit the insertion depth of the carrier portion 120 of the reinforcer 100 within the cavity 170 defined by inner walls 180 of structural member 160. It is to be understood that the base 110 may be larger or smaller than the illustrated base 110, and that the base 110 may be omitted entirely, depending on particular application needs.
- a plurality of adhesive beads 130 are arranged in a series of parallel rows along the exterior of the carrier 120.
- the plurality of rows of adhesive beads 130 are positioned such that they will contact one or more inner walls 180 of the structural member 160, when the carrier 120 is positioned within the cavity 170.
- the size of the gap that is defined between the carrier 120 and the one or more inner walls 180 of the structural member 160 when the carrier 120 is positioned within the cavity 170 may be determined by the design of the carrier 120, and is between 4 mm and 0.5 mm. In one exemplary approach, the size of the gap may be between about 2 mm and about 4 mm.
- the design of the gap may be influenced, in part, by the production methods used for the structural reinforcer 100 and the structural member 160, by the adhesive 130 used, as well as other factors.
- the adhesive beads 130 When the carrier 120 is positioned in the cavity 170, the adhesive beads 130 may be deformed, or displaced, from an initial position. When the adhesive beads 130 are deformed or displaced, two or more separate adhesive beads 130 may connect, creating one or more larger adhesive beads 130. Additionally, or alternatively, adhesive beads 130 may be positioned such that one or more channels are defined between the carrier 120 and the one or more interior walls 180, to allow fluid, such as e-coat fluid, to flow therein.
- FIG. 2 illustrates another exemplary reinforcer 100.
- Reinforcer 100 includes a base 110 with a carrier 120 attached thereto.
- a plurality of round adhesive beads 130 are positioned at various locations along exterior faces of the carrier 120.
- the adhesive beads 130 are positioned such that, when the carrier portion 120 of the structural reinforcer 100 is positioned within the cavity 170 defined by inner walls 180 of structural member 160, the adhesive beads 130 will contact the one or more of the inner walls 180.
- the size, location and quantity of adhesive beads 130 may be chosen based on particular application requirements.
- Two or more of the adhesive beads 130 may be positioned such that, upon insertion of the carrier 120 into the cavity 170, the two or more adhesive beads 130 will be displaced and will contact each other, thereby forming a larger effective adhesive bead 130.
- adhesive beads 130 may be positioned such that, upon insertion of the carrier 120 into the cavity 170, the adhesive beads 130 may remain separate, providing one or more channels for fluid, such as e-coat fluid, to flow through.
- Figure 3 illustrates an exemplary reinforcer 100, including a base portion 110 and a carrier portion 120, configured to provide structural support to a structural member 160.
- Inner walls 180 of the structural member 160 define a cavity 170 therein.
- Adhesive beads 130 are applied in generally parallel rows along inner faces 180 of structural member 160.
- the carrier portion 120 is positioned within the cavity 170, proximate the one or more inner walls 180.
- the adhesive beads 130 include a bead thickness that is greater than the width of a gap defined between the carrier 120 and one or more inner walls 180.
- the adhesive beads 130 When the carrier 120 is positioned within the cavity 170, the adhesive beads 130 thus contact both the carrier 120 and one or more inner walls 180, thereby deforming the adhesive beads 130.
- the adhesive 130 may thus adhere the carrier 120 within the cavity 170, which adheres the structural reinforcer 100 to the structural member 160.
- Figure 4 illustrates a cross-sectional end view of an exemplary system including a reinforcer 100 having a base portion 110 and a carrier portion 120.
- the illustrated reinforcer 100 is positioned proximate a structural member 160.
- the carrier portion 120 of the reinforcer is positioned within a cavity 170 defined by one or more inner walls 180 of the structural member 160.
- Adhesive beads 130 may be displaced within the gap 185, by positioning the carrier 120 proximate the inner wall 180 of the structural member 160, such that the adhesive beads 130 are deformed and substantially fill the entire gap 185.
- adhesive beads 130 may be positioned such that one or more passages are maintained within gap 185 when carrier 120 is positioned within the cavity 170, which may allow fluid, such as e-coat fluid, to flow between the carrier 120 and the one or more inner walls 180 of the structural member 160.
- the gap 185 between the carrier 120 and the one or more inner walls 180 may be determined in part by the design of the carrier 120, the assembly tolerances of the carrier 120 and the structural member 160, and the particular application.
- the gap 185 between the carrier 120 and the structural member 160 is between 4 mm and 0.5 mm. In another exemplary approach, the gap 185 may be between about 2 mm and 4 mm.
- Placement of adhesive beads 130 may allow selective adhesion of the structural reinforcer 100 to the structural member 160 at one or more locations along the outer surface of the carrier 120, to allow localized strengthening of the structural member 160, while conserving adhesive 130.
- Adhesive beads 130 may be positioned such that one or more individual beads 130 may combine with one or more additional beads 130 when the carrier 120 is positioned within the cavity 170.
- Figure 5 illustrates an end view of a reinforcer 100 according to an exemplary approach.
- the reinforcer 100 includes a base 110, and a carrier 120 positioned thereon.
- the carrier 120 includes a plurality of adhesive beads 130 disposed thereon.
- a plurality of adhesive beads 130 are covered by a protective film 140.
- the protective film 140 may, for example, protect the adhesive beads 130 from dust, moisture, or other contaminants, prevent the beads 130 from adhering to one or more elements prior to installing the reinforcer 100 within the structural member 160, etc. Additionally, or alternatively, the film 140 may prevent adhesive beads 130 from curing until the film 140 is removed.
- Protective film 140 may thus allow adhesive beads 130 to be disposed on a carrier 120, or a structural member 160, prior to placing carrier 120 into a cavity 170, without the adhesive 130 prematurely curing. Such an approach may be particularly useful for aftermarket or service applications, or for other applications where an adhesive may cure when exposed to air, or to atmospheric moisture. For example, adhesive beads 130 may be applied to a carrier 120 at a factory, and the structural reinforcer 100 may subsequently be shipped to a service location, without the adhesive 130 beginning to cure. Protective film 140 may be removed prior to placing carrier 120 within a cavity 170, such as by peeling or cutting the film 140, etc. Film 140 may also be removed after the carrier 120 of structural reinforcer 100 has been positioned within cavity 170, such as through application of heat, pressure, chemicals, or other suitable means.
- Figure 6 illustrates an end view of a reinforcer 100 according to an exemplary approach.
- the reinforcer 100 includes a base 110, and a carrier 120 positioned thereon.
- a plurality of adhesive beads 130 are disposed across the carrier 120.
- Each of the plurality of adhesive beads 130 may be covered by a respective protective film 150.
- Providing individual protective films 140 for adhesive beads 130 may further protect the integrity of a reinforcer 100. For example, by providing individual protective films 140, should an individual film 140 may be punctured or flawed, the remaining films 140, and the respective adhesive beads 130 they protect, may remain intact.
- Figures 7a and 7b illustrate a partial view of a reinforcer 100.
- Reinforcer 100 includes a carrier portion 120 having one or more protrusions 190 mounted thereon.
- One or more adhesive beads 130 may be disposed proximate the one or more protrusions 190.
- the protrusions 190 may assist in directing the flow of adhesive beads 130 when the adhesive beads 130 are deformed, such as when a carrier 120 is positioned within the cavity 170.
- Figure 7a illustrates the carrier 120 prior to the installation of the reinforcer 100.
- An adhesive bead 130 is illustrated in an undeformed position, between two protrusions 190.
- Figure 7b illustrates the reinforcer 100 of Figure 7a after the carrier 120 has been positioned within cavity 170.
- the adhesive bead 130 has been deformed, and has taken a shape defined in part by protrusions 190.
- the protrusions 190 may thus be configured to direct the flow of the adhesive 130, when the structural reinforcer 100 is installed in a structural
- Figure 8 is a flowchart illustrating an exemplary method 200 of reinforcing a cavity of a structural element, such as cavity 170 of structural member 160, using a reinforcer such as reinforcer 100.
- a reinforcer 100 is designed such that the carrier 120 of the reinforcer 100 conforms closely to inner walls 180 of the structural member 160.
- one or more adhesive beads 130 are extruded onto one or more outer faces of carrier 120. Additionally, or alternatively, adhesive beads 130 may be extruded onto one or more inner walls 180 of a structural member 160. Adhesive 130 may be extruded automatically, for example, using an automated assembly line, or may be extruded manually, such as by a user employing an extruder gun.
- a protective film 140 is extruded onto one or more adhesive beads 130.
- the protective film 140 may be extruded onto one or more adhesive beads 130 in concert with extrusion of adhesive beads 130, or may be disposed thereon after the adhesive beads 130 have been extruded.
- the protective film 140 is removed.
- the film 140 may be removed by, for example, peeling off the film 140, or by the application of an element such as heat or a chemical to the film.
- the structural reinforcer 100 may, for example, be transported from a first location to another, or that time may elapse, between the application of the film 140 in step 230 and the subsequent removal of the film 140 in step 240.
- the carrier portion 120 of the reinforcer 100 is placed within a cavity 170 defined by one or more inner walls 180 of a structural member 160.
- one or more adhesive beads 130 may be displaced and / or deformed as the gap between the carrier 120 and one or more inner walls 180 of structural member 160 is reduced.
- the adhesive beads 130 may begin to cure. Curing of the adhesive beads 130 may begin automatically, for example, upon exposure of the adhesive beads 130 to air or moisture. Curing of the adhesive beads 130 may also be activated or accelerated through the application of one or more elements, such as heat, light, chemicals, etc. For example, adhesive beads 130 may be activated through heat, such as the heat associated with baking during an e-coat or painting process. Curing the adhesive beads 130 may adhere the structural reinforcer 100 to the structural member 160.
- the surface of the carrier 120 of the reinforcer and / or the walls 180 of the structural member may be treated with surface treatments to improve the bonding of the adhesive 130.
- Various surface treatments include sandblasting, using an abrasive, pickling, using plasma, using a corona discharge, flaming, adhesive abrading, chromic acid etching, iodine treatment, use of primers, sodium treatment, surface grafting, surface roughening, thermal treatment, transcrystalline growth, and/or UV exposure.
- the surface treatment may also help improve the bonding of other materials.
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- Combustion & Propulsion (AREA)
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- Structural Engineering (AREA)
- Architecture (AREA)
- Adhesives Or Adhesive Processes (AREA)
- Laminated Bodies (AREA)
- Body Structure For Vehicles (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
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Description
- The present disclosure is directed toward methods and systems for providing structural reinforcement.
- Many products have bodies or housings with hollow cavities therein. For example, various consumer appliances and vehicles may have hollow cavities formed between inner and outer panels of the bodies or housings, such as in pillars or within frame members. In particular, some structural members of automobile bodies include a variety of pillars, members, rails, beams, posts, etc. (collectively referred to as "cavities") connected by one or more nodes. Such hollow pillars, beams, etc., often assist in reducing the overall weight of the final product, as well as reducing material costs. However, these cavities often result in a structural member that lacks sufficient strength or energy-absorbing characteristics.
- One way to compensate for a weakened structural member is to provide a structural reinforcer within the cavity of the member. Structural reinforcers often include a carrier with an expandable material configured to expand and mold to an inner surface of the structural member. The carrier portion is typically a molded component made from nylon, glass-reinforced nylon, metal, or some combination thereof, and is designed to be lightweight yet stiff. The carrier may also include a plurality of ribs configured to increase the carrier's response to specific stresses.
- While effective, the molded carrier structural reinforcers described above have drawbacks. For instance, expandable foam layers generally are relatively large, and provide only moderate strength increases, particularly with regard to shear and tensile stresses. The portions of the reinforcer which are foamable material lack the comparable strength of the molded carrier portion. Further, in order to achieve sufficient expansion of the foam, such reinforcers generally require a large gap between the carrier and an interior wall of a cavity to be reinforced. The required gap between the molded carrier and the interior walls defining the cavity is generally a minimum of 6 - 10 mm. With a gap of this size, it is possible that the gap will not be properly sealed when the foam expands, due to conditions such as high assembly tolerances, variations in baking conditions, etc. If, for example, the foam does not expand uniformly, it is possible that portions of the gap will remain unsealed, or that the carrier will not be properly secured within the cavity. Further, it is difficult to design a foaming structural reinforcer including one or more channels within the cavity, to allow fluid, such as e-coat fluid, to flow therethrough. Additionally, expandable foam reinforcers generally provide only moderate reinforcement with regard to shear and tensile loads.
- Other reinforcers have been designed using an injectable adhesive that flows between the reinforcer and the structural member, to adhere the reinforcer thereto. Using an injectable adhesive allows portions of the gap between a carrier and one or more inner walls of the cavity to be reduced, as it is not necessary to provide room for expansion of the expandable foam across the entire carrier. However, methods including injectable adhesives also have drawbacks. Current methods using injectable adhesives generally require introduction of a sealing material between the carrier and one or more inner walls of the cavity, to prevent the injectable adhesive from flowing out of the cavity. The sealing material generally consists of an expandable foam or mastic. This process thus involves additional steps, and additional materials, including the application of sealing material, and the curing of sealing material, in addition to the subsequent injection and curing of the adhesive material. This requires additional time and expense to create a reinforced part. This also necessitates that timing be more closely controlled, as adhesive generally cannot be injected until the sealing material is at least partially cured. Further, injecting adhesive into a cavity generally fills the entire gap with adhesive, making it difficult to provide channels for e-coat flow.
US 6 058 673 A discloses a reinforcement for hollow structural elements, with an I-shaped cross section.GB 2 375 328 A WO 2006/091794 A1 discloses a bonded hybrid structure, in which a plastic component is bonded to a metal component to form a lightweight reinforced structure. - The present disclosure is directed to systems and methods for providing structural reinforcement. More specifically, the disclosure is directed to structural reinforcers configured to be adhesively secured within a cavity. The structural reinforcer may include a carrier conforming generally in shape to one or more inner walls defining the cavity. An adhesive is placed on a reinforcer and / or a structural member. The adhesive may retain a substantially stable shape prior to insertion of the reinforcer within the structural member. The present disclosure allows a much closer fit between the carrier of the reinforcer and the inner walls defining a cavity within the structural member. The present disclosure also eliminates the need to use expandable foams or mastics as a sealer along with the adhesive. The present disclosure also simplifies the inclusion of channels between the reinforcer and the structure, for fluid flow, and allows simplified design for localized placement of adhesive. This may allow a reinforcer to be designed using less adhesive, leading to cost savings.
- A protective film may also be provided over some or all of the adhesive, and may protect the adhesive from dust, moisture, contaminants, or contact with other elements. This may, for example, allow for adhesive to be placed on a service part prior to the part leaving a factory, while preventing the adhesive curing prematurely.
- While the claims are not limited to the illustrated examples, an appreciation of various aspects is best gained through a discussion of various examples thereof. Referring now to the drawings, a variety of examples are shown in detail. Although the drawings represent the various illustrations, the drawings are not necessarily to scale and certain features may be exaggerated to better illustrate and explain an innovative aspect of an example. Further, the examples described herein are not intended to be exhaustive or otherwise limiting or restricting to the precise form and configuration shown in the drawings and disclosed in the following detailed description. Exemplary illustrations are described in detail by referring to the drawings as follows.
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FIG. 1 illustrates an exemplary reinforcer and structural member wherein adhesive is extruded in a series of parallel beads on the carrier; -
FIG. 2 Illustrates an exemplary reinforcer and structural member wherein adhesive is extruded in a series of circular plots on the carrier; -
FIG. 3 illustrates an exemplary reinforcer and structural member wherein adhesive is extruded on the structural member; -
FIG. 4 illustrates an end view of an exemplary reinforcer positioned within a structural member; -
FIG. 5 illustrates an exemplary reinforcer and structural member including a protective film over adhesive beads; -
FIG. 6 illustrates an exemplary reinforcer and structural member including a plurality of protective films; -
FIGS. 7A and 7B illustrate an exemplary reinforcer and structural member; -
FIG. 8 is a flowchart illustrating a method of fabricating a reinforcer according to an exemplary approach; - Without limitation thereto, exemplary approaches described herein include a structural reinforcer having a carrier configured to provide reinforcement to a structural member. The structural member may be, for instance, a beam, a channel, a pillar, etc., within an appliance, a vehicle, such as an automobile, etc. The reinforcer is adhered to the structural member using an adhesive.
- The reinforcer may be made of metal, such as aluminum or steel, plastic, nylon, glass-reinforced nylon, a foam structure, an organic structure, or some combination thereof. In one exemplary approach, the reinforcer is made of a thermoplastic material. The reinforcer may be made through extrusion, through injection molding, or through other suitable process. The reinforcer may include one or more ribs therein to provide localized strengthening, based on a particular application. At least a portion of the reinforcer may be designed to conform closely in shape to a portion of the structural member to which it is to be adhered. For example, one or more outer faces of the carrier portion of the structural reinforcer may be configured to conform generally to one or more inner faces defining a cavity within the structural member. For instance, when the structural reinforcer is positioned proximate the structural member, the gap between portions of the carrier, and one or more inner faces of the structural member to which the carrier is to be adhered, between 4 mm and 0.5 mm. The size of the gap may be determined or designed based on application needs, production methods, etc. In one approach the gap may be designed to between about 2 mm and about 4 mm.
- An adhesive is used to secure the reinforcer to the structural member. The adhesive may be applied to the reinforcer, such as along an outer face of the carrier, and / or to the structural member, such as along one or more inner walls defining a cavity in the structural member. The adhesive may be applied prior to placement of the reinforcer proximate the structural member, which may position the carrier member within the cavity. The adhesive may cure while the carrier is positioned within the cavity, thereby adhering the structural reinforcer to the structural member.
- Adhesive may be applied as one or more adhesive beads, or plots, on one or more faces of the carrier, and / or on one or more inner faces of the structural member. The length, width, thickness, shape, cross-section, surface, quantity and placement of the adhesive beads or plots may vary as appropriate for any particular application, based on application parameters such as minimizing cost, maximizing strength, speeding assembly time, etc. For example, beads may be applied as a continuous semicircular bead, a series of parallel lines, a series of contiguous plots, a series of round adhesive plots, a series of concentric circles, in a zigzag pattern, or according to any other design. The thickness of adhesive beads may be determined based on specific application needs. In one exemplary approach, the bead thickness is a minimum of about 150% of the width of the gap defined by the opposing surfaces which are mated by the adhesive.
- The adhesive employed may be any of a number of adhesives. The chosen adhesive may be substantially non-foaming. That is, the chosen adhesive may expand less than about 20% when curing. In one exemplary approach, the adhesive NEr, 10.01.2018 may expand less than about 5% when curing. In another exemplary approach, the adhesive is non-expandable. The chosen adhesive may have a viscosity that is high enough that the adhesive will retain its bead shape until the reinforcer is positioned within the structural member, yet low enough that the adhesive may be at least partially deformed or displaced upon insertion of the reinforcer within the structural member. In one approach the adhesive may have a paste-like consistency prior to curing, and / or may be tacky. In another approach, the adhesive may act like a Bingham plastic, retaining a substantially stable shape prior to application of sufficient stress. The chosen adhesive may cure through exposure to air, atmospheric moisture, another chemical, heat, light, or according to any other appropriate curing method. According to one approach, the adhesive may be chosen such that the adhesive will cure when exposed to heat, such as during a baking or e-coat process. The adhesive may be, for example, a polymer composition including at least a resin and a hardener. For instance, the adhesive may be a polyurethane composition, a polyurethane and polyol isocyanate composition, an acrylate composition, an epoxide composition, etc. The adhesive may include an epoxy resin and hardener, such as a polyisocyanate or polyamine hardener, microencapsulated acrylic or methacrylate, etc. Suitable adhesives include those adhesives described in patent application serial number
WO/2008/077944 . - The adhesive may be extruded on the carrier and / or the structural member through an automated process, such as by a robot on an assembly line, or manually, such as by an operator using an extruder gun. The adhesive may be heated to assist in extrusion, or may be applied at ambient temperature. In one exemplary approach, the adhesive may be provided to an assembly location in drums. The adhesive may be provided, for example, in the form of a paste, or a viscous material.
- A protective film may be applied over the adhesive, and may prevent the adhesive from curing prematurely, prevent dust or other contaminants from sticking to the adhesive, protect the adhesive from exposure to moisture or air, and / or ensure shelf life and adhesion properties. The protective film may be co-extruded with the adhesive, or may be applied on top of the extruded adhesive. According to one exemplary approach, the protective film may be a plastic, such as polyethylene. The protective film may be removed prior to, during, or after placing the structural reinforcer proximate the structural member. The protective film may be removed, for example, by peeling the protective film from the adhesive, by cutting the film from the adhesive, by the application of heat, chemicals, light, etc., or through other appropriate means.
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Figure 1 illustrates anexemplary reinforcer 100 having a base 110 and acarrier 120 connected thereto. Theexemplary carrier portion 120 conforms generally in shape to acavity 170 defined by one or moreinterior walls 180 of astructural member 160. The base 110 may include one or more faces that are substantially coplanar with one or more faces ofstructural member 160, and configured to butt against thestructural member 160 to limit the insertion depth of thecarrier portion 120 of thereinforcer 100 within thecavity 170 defined byinner walls 180 ofstructural member 160. It is to be understood that the base 110 may be larger or smaller than the illustratedbase 110, and that the base 110 may be omitted entirely, depending on particular application needs. In the exemplary approach ofFigure 1 , a plurality ofadhesive beads 130 are arranged in a series of parallel rows along the exterior of thecarrier 120. The plurality of rows ofadhesive beads 130 are positioned such that they will contact one or moreinner walls 180 of thestructural member 160, when thecarrier 120 is positioned within thecavity 170. The size of the gap that is defined between thecarrier 120 and the one or moreinner walls 180 of thestructural member 160 when thecarrier 120 is positioned within thecavity 170 may be determined by the design of thecarrier 120, and is between 4 mm and 0.5 mm. In one exemplary approach, the size of the gap may be between about 2 mm and about 4 mm. The design of the gap may be influenced, in part, by the production methods used for thestructural reinforcer 100 and thestructural member 160, by the adhesive 130 used, as well as other factors. When thecarrier 120 is positioned in thecavity 170, theadhesive beads 130 may be deformed, or displaced, from an initial position. When theadhesive beads 130 are deformed or displaced, two or more separateadhesive beads 130 may connect, creating one or more largeradhesive beads 130. Additionally, or alternatively,adhesive beads 130 may be positioned such that one or more channels are defined between thecarrier 120 and the one or moreinterior walls 180, to allow fluid, such as e-coat fluid, to flow therein. -
Figure 2 illustrates anotherexemplary reinforcer 100.Reinforcer 100 includes a base 110 with acarrier 120 attached thereto. A plurality of roundadhesive beads 130 are positioned at various locations along exterior faces of thecarrier 120. Theadhesive beads 130 are positioned such that, when thecarrier portion 120 of thestructural reinforcer 100 is positioned within thecavity 170 defined byinner walls 180 ofstructural member 160, theadhesive beads 130 will contact the one or more of theinner walls 180. The size, location and quantity ofadhesive beads 130 may be chosen based on particular application requirements. Two or more of theadhesive beads 130 may be positioned such that, upon insertion of thecarrier 120 into thecavity 170, the two or moreadhesive beads 130 will be displaced and will contact each other, thereby forming a larger effectiveadhesive bead 130. Additionally, or alternatively,adhesive beads 130 may be positioned such that, upon insertion of thecarrier 120 into thecavity 170, theadhesive beads 130 may remain separate, providing one or more channels for fluid, such as e-coat fluid, to flow through. -
Figure 3 illustrates anexemplary reinforcer 100, including abase portion 110 and acarrier portion 120, configured to provide structural support to astructural member 160.Inner walls 180 of thestructural member 160 define acavity 170 therein.Adhesive beads 130 are applied in generally parallel rows alonginner faces 180 ofstructural member 160. When thereinforcer 100 is positioned proximate thestructural member 160, thecarrier portion 120 is positioned within thecavity 170, proximate the one or moreinner walls 180. Theadhesive beads 130 include a bead thickness that is greater than the width of a gap defined between thecarrier 120 and one or moreinner walls 180. When thecarrier 120 is positioned within thecavity 170, theadhesive beads 130 thus contact both thecarrier 120 and one or moreinner walls 180, thereby deforming theadhesive beads 130. The adhesive 130 may thus adhere thecarrier 120 within thecavity 170, which adheres thestructural reinforcer 100 to thestructural member 160. -
Figure 4 illustrates a cross-sectional end view of an exemplary system including areinforcer 100 having abase portion 110 and acarrier portion 120. Theillustrated reinforcer 100 is positioned proximate astructural member 160. Thecarrier portion 120 of the reinforcer is positioned within acavity 170 defined by one or moreinner walls 180 of thestructural member 160. When thereinforcer 100 is positioned proximate thestructural member 160, there is agap 185 defined between at least a portion of thecarrier 120 and at least oneinner wall 180 of thestructural member 160.Adhesive beads 130 may be displaced within thegap 185, by positioning thecarrier 120 proximate theinner wall 180 of thestructural member 160, such that theadhesive beads 130 are deformed and substantially fill theentire gap 185. It is to be understood that this is by way of example only, and thatadhesive beads 130 may be positioned such that one or more passages are maintained withingap 185 whencarrier 120 is positioned within thecavity 170, which may allow fluid, such as e-coat fluid, to flow between thecarrier 120 and the one or moreinner walls 180 of thestructural member 160. Thegap 185 between thecarrier 120 and the one or moreinner walls 180 may be determined in part by the design of thecarrier 120, the assembly tolerances of thecarrier 120 and thestructural member 160, and the particular application. Thegap 185 between thecarrier 120 and thestructural member 160 is between 4 mm and 0.5 mm. In another exemplary approach, thegap 185 may be between about 2 mm and 4 mm. Placement ofadhesive beads 130 may allow selective adhesion of thestructural reinforcer 100 to thestructural member 160 at one or more locations along the outer surface of thecarrier 120, to allow localized strengthening of thestructural member 160, while conserving adhesive 130.Adhesive beads 130 may be positioned such that one or moreindividual beads 130 may combine with one or moreadditional beads 130 when thecarrier 120 is positioned within thecavity 170. -
Figure 5 illustrates an end view of areinforcer 100 according to an exemplary approach. Thereinforcer 100 includes abase 110, and acarrier 120 positioned thereon. Thecarrier 120 includes a plurality ofadhesive beads 130 disposed thereon. In the exemplary approach ofFigure 5 , a plurality ofadhesive beads 130 are covered by aprotective film 140. Theprotective film 140 may, for example, protect theadhesive beads 130 from dust, moisture, or other contaminants, prevent thebeads 130 from adhering to one or more elements prior to installing thereinforcer 100 within thestructural member 160, etc. Additionally, or alternatively, thefilm 140 may preventadhesive beads 130 from curing until thefilm 140 is removed.Protective film 140 may thus allowadhesive beads 130 to be disposed on acarrier 120, or astructural member 160, prior to placingcarrier 120 into acavity 170, without the adhesive 130 prematurely curing. Such an approach may be particularly useful for aftermarket or service applications, or for other applications where an adhesive may cure when exposed to air, or to atmospheric moisture. For example,adhesive beads 130 may be applied to acarrier 120 at a factory, and thestructural reinforcer 100 may subsequently be shipped to a service location, without the adhesive 130 beginning to cure.Protective film 140 may be removed prior to placingcarrier 120 within acavity 170, such as by peeling or cutting thefilm 140, etc.Film 140 may also be removed after thecarrier 120 ofstructural reinforcer 100 has been positioned withincavity 170, such as through application of heat, pressure, chemicals, or other suitable means. -
Figure 6 illustrates an end view of areinforcer 100 according to an exemplary approach. Thereinforcer 100 includes abase 110, and acarrier 120 positioned thereon. A plurality ofadhesive beads 130 are disposed across thecarrier 120. Each of the plurality ofadhesive beads 130 may be covered by a respectiveprotective film 150. Providing individualprotective films 140 foradhesive beads 130 may further protect the integrity of areinforcer 100. For example, by providing individualprotective films 140, should anindividual film 140 may be punctured or flawed, the remainingfilms 140, and the respectiveadhesive beads 130 they protect, may remain intact. -
Figures 7a and 7b illustrate a partial view of areinforcer 100.Reinforcer 100 includes acarrier portion 120 having one ormore protrusions 190 mounted thereon. One or moreadhesive beads 130 may be disposed proximate the one ormore protrusions 190. Theprotrusions 190 may assist in directing the flow ofadhesive beads 130 when theadhesive beads 130 are deformed, such as when acarrier 120 is positioned within thecavity 170.Figure 7a illustrates thecarrier 120 prior to the installation of thereinforcer 100. Anadhesive bead 130 is illustrated in an undeformed position, between twoprotrusions 190.Figure 7b illustrates thereinforcer 100 ofFigure 7a after thecarrier 120 has been positioned withincavity 170. Theadhesive bead 130 has been deformed, and has taken a shape defined in part byprotrusions 190. Theprotrusions 190 may thus be configured to direct the flow of the adhesive 130, when thestructural reinforcer 100 is installed in astructural member 160. -
Figure 8 is a flowchart illustrating anexemplary method 200 of reinforcing a cavity of a structural element, such ascavity 170 ofstructural member 160, using a reinforcer such asreinforcer 100. Atstep 210, areinforcer 100 is designed such that thecarrier 120 of thereinforcer 100 conforms closely toinner walls 180 of thestructural member 160. - At
step 220, one or moreadhesive beads 130 are extruded onto one or more outer faces ofcarrier 120. Additionally, or alternatively,adhesive beads 130 may be extruded onto one or moreinner walls 180 of astructural member 160. Adhesive 130 may be extruded automatically, for example, using an automated assembly line, or may be extruded manually, such as by a user employing an extruder gun. - At
step 230, aprotective film 140 is extruded onto one or moreadhesive beads 130. Theprotective film 140 may be extruded onto one or moreadhesive beads 130 in concert with extrusion ofadhesive beads 130, or may be disposed thereon after theadhesive beads 130 have been extruded. - At
step 240, theprotective film 140 is removed. Thefilm 140 may be removed by, for example, peeling off thefilm 140, or by the application of an element such as heat or a chemical to the film. It is to be understood that thestructural reinforcer 100 may, for example, be transported from a first location to another, or that time may elapse, between the application of thefilm 140 instep 230 and the subsequent removal of thefilm 140 instep 240. - At
step 250, thecarrier portion 120 of thereinforcer 100 is placed within acavity 170 defined by one or moreinner walls 180 of astructural member 160. As thecarrier 120 is positioned within thecavity 170, one or moreadhesive beads 130 may be displaced and / or deformed as the gap between thecarrier 120 and one or moreinner walls 180 ofstructural member 160 is reduced. - At
step 260, theadhesive beads 130 may begin to cure. Curing of theadhesive beads 130 may begin automatically, for example, upon exposure of theadhesive beads 130 to air or moisture. Curing of theadhesive beads 130 may also be activated or accelerated through the application of one or more elements, such as heat, light, chemicals, etc. For example,adhesive beads 130 may be activated through heat, such as the heat associated with baking during an e-coat or painting process. Curing theadhesive beads 130 may adhere thestructural reinforcer 100 to thestructural member 160. - In addition to the embodiments disclosed, the surface of the
carrier 120 of the reinforcer and / or thewalls 180 of the structural member may be treated with surface treatments to improve the bonding of the adhesive 130. Various surface treatments include sandblasting, using an abrasive, pickling, using plasma, using a corona discharge, flaming, adhesive abrading, chromic acid etching, iodine treatment, use of primers, sodium treatment, surface grafting, surface roughening, thermal treatment, transcrystalline growth, and/or UV exposure. The surface treatment may also help improve the bonding of other materials.
Claims (11)
- A system for reinforcing a structural member, comprising:a structural reinforcer (100) including a rigid carrier portion (120) made of at least one of metal, plastic, nylon, glass-reinforced nylon, and an organic material;at least a portion of the carrier portion (120) configured to conform generally to one or more inner walls (180) defining a cavity (170) in a structural member, the structural member generally made of at least metal;wherein the gap (185) between said at least a portion of the carrier (120) and the one or more inner walls (180) of the cavity (170) is between 4 mm and 0.5 mm when the carrier (120) is positioned within the cavity (170); andan adhesive (130), which is generally tacky to the touch, extruded at one or more locations on at least one of the carrier (120) and an inner wall (180), prior to insertion of the carrier (120) within the cavity (170), to adhere the carrier (120) to the one or more inner walls (180) of the cavity (170) when the carrier (120) is positioned therein, wherein the adhesive (130) is non-expandable, and wherein the adhesive (130) is configured to cure in an e-coat process when exposed to heat;wherein adhering the carrier (120) within the cavity (170) increases the strength of the structural member.
- The system of claim 1, wherein the adhesive (130) is extruded as one or more beads or plots on at least one of the carrier (120) and the one or more inner walls (180).
- The system of claims 1 - 2, wherein the adhesive (130) is arranged such that when carrier (120) is adhered to the one or more inner walls (180), a channel is maintained between a portion of the carrier (120) and the one or more inner walls (180) defining the cavity (170), to allow fluid to flow therebetween.
- The system of claims 1-3, wherein the adhesive (130) is a polymer composition.
- The system of claims 1-3, wherein the adhesive (130) is formed from a mixture of thermoplastic resins and epoxy resins.
- The system of claim 1, wherein the adhesive (130) has a viscosity high enough that the adhesive (130) may retain an extruded shape until carrier (120) is positioned within cavity (170), and low enough that the adhesive (130) may be deformed or displaced when carrier (120) is positioned within cavity (170).
- The system of claim 1, wherein the adhesive (130) has a maximum initial bead thickness of less than about 12 millimeters.
- The system of claim 1, further comprising one or more protrusions (190) defined on an outer surface of the carrier (120), the one or more protrusions (190) configured to direct flow of the adhesive (130) when the carrier (120) is installed within the cavity (170).
- A method of reinforcing a structural member comprising:providing a reinforcer (100) having a carrier (120) made of at least one of metal, plastic, nylon, glass-reinforced nylon, and an organic material, the carrier (120) configured to conform generally to one or more inner walls (180) defining a cavity (170) within a structural member (160), the structural member (160) generally made of at least metal;extruding one or more adhesive beads (130) on at least one of the carrier (120) and the one or more inner walls (180); andplacing the carrier (120) within the cavity (170) proximate the one or more inner walls (180) thereby deforming the one or more adhesive beads (130);wherein the gap (185) between at least a portion of the carrier (120) and the one or more inner walls (180) is between 4 mm and 0.5 mm when the carrier (120) is positioned within the cavity (170); andwherein the adhesive is non-expandable and generally tacky to the touch when extruded, and wherein the one or more adhesive beads (130) are configured to cure upon exposure to heat.
- The method of claim 9, wherein the one or more adhesive beads (130) have a maximum initial bead thickness of less than 12 mm.
- The method of claim 9 or 10, further comprising coating one or more of the adhesive beads (130) with one or more protective films (140) contemporaneously with extruding one or more adhesive beads (130) on at least one of the carrier (120) and the one or more inner walls (180).
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP09809354.5A EP2334540B1 (en) | 2008-09-01 | 2009-09-01 | Bonding with adhesive beads or plots |
EP18179077.5A EP3421330A1 (en) | 2008-09-01 | 2009-09-01 | Bonding with adhesive beads or plots |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP08163412A EP2159136A1 (en) | 2008-09-01 | 2008-09-01 | Bonding with adhesive beads or plots |
PCT/EP2009/061270 WO2010023324A1 (en) | 2008-09-01 | 2009-09-01 | Bonding with adhesive beads or plots |
EP09809354.5A EP2334540B1 (en) | 2008-09-01 | 2009-09-01 | Bonding with adhesive beads or plots |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
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EP18179077.5A Division-Into EP3421330A1 (en) | 2008-09-01 | 2009-09-01 | Bonding with adhesive beads or plots |
EP18179077.5A Division EP3421330A1 (en) | 2008-09-01 | 2009-09-01 | Bonding with adhesive beads or plots |
Publications (2)
Publication Number | Publication Date |
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EP2334540A1 EP2334540A1 (en) | 2011-06-22 |
EP2334540B1 true EP2334540B1 (en) | 2018-08-15 |
Family
ID=40225494
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP08163412A Withdrawn EP2159136A1 (en) | 2008-09-01 | 2008-09-01 | Bonding with adhesive beads or plots |
EP09809354.5A Active EP2334540B1 (en) | 2008-09-01 | 2009-09-01 | Bonding with adhesive beads or plots |
EP18179077.5A Withdrawn EP3421330A1 (en) | 2008-09-01 | 2009-09-01 | Bonding with adhesive beads or plots |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP08163412A Withdrawn EP2159136A1 (en) | 2008-09-01 | 2008-09-01 | Bonding with adhesive beads or plots |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP18179077.5A Withdrawn EP3421330A1 (en) | 2008-09-01 | 2009-09-01 | Bonding with adhesive beads or plots |
Country Status (8)
Country | Link |
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US (1) | US9708013B2 (en) |
EP (3) | EP2159136A1 (en) |
JP (1) | JP5792618B2 (en) |
KR (1) | KR101704806B1 (en) |
CN (2) | CN102137786B (en) |
BR (1) | BRPI0917843B1 (en) |
ES (1) | ES2694046T3 (en) |
WO (1) | WO2010023324A1 (en) |
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CN102765424A (en) * | 2012-07-02 | 2012-11-07 | 奇瑞汽车股份有限公司 | Welding structure and welding method for cavity part of vehicle body outer plate |
WO2014124924A1 (en) * | 2013-02-15 | 2014-08-21 | Sika Technology Ag | Process and arrangement for making a reinforced structural member |
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GB201318595D0 (en) | 2013-10-21 | 2013-12-04 | Zephyros Inc | Improvements in or relating to laminates |
CN106536150B (en) | 2014-04-30 | 2020-01-24 | 泽菲罗斯公司 | Extrusion reinforcement |
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EP3370631A4 (en) * | 2015-11-04 | 2019-05-15 | Custom Medical Applications, Inc. | Needles and related assemblies and methods |
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CN110753655B (en) * | 2017-06-22 | 2022-10-28 | Sika技术股份公司 | Reinforcing element, system of reinforced structural elements and method for reinforcing structural elements |
BR112020013504A2 (en) | 2018-01-02 | 2020-12-01 | Zephyros, Inc. | reinforcement set, method for forming a panel reinforcement and method for reinforcing panel |
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JP7120175B2 (en) * | 2019-07-18 | 2022-08-17 | Jfeスチール株式会社 | Automobile collision energy absorbing part, method for manufacturing the automobile collision energy absorbing part |
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JP7238867B2 (en) * | 2020-08-18 | 2023-03-14 | Jfeスチール株式会社 | Automobile collision energy absorbing part, method for manufacturing the automobile collision energy absorbing part |
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WO2006091794A1 (en) * | 2005-02-25 | 2006-08-31 | Dow Global Technologies, Inc. | Bonded hybrid structure |
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US9708013B2 (en) | 2017-07-18 |
ES2694046T3 (en) | 2018-12-17 |
KR20110050692A (en) | 2011-05-16 |
KR101704806B1 (en) | 2017-02-08 |
US20110236616A1 (en) | 2011-09-29 |
BRPI0917843B1 (en) | 2020-09-24 |
CN102137786A (en) | 2011-07-27 |
WO2010023324A1 (en) | 2010-03-04 |
BRPI0917843A2 (en) | 2015-11-24 |
JP2012501363A (en) | 2012-01-19 |
CN102137786B (en) | 2016-11-09 |
EP2334540A1 (en) | 2011-06-22 |
CN103909975A (en) | 2014-07-09 |
EP3421330A1 (en) | 2019-01-02 |
EP2159136A1 (en) | 2010-03-03 |
JP5792618B2 (en) | 2015-10-14 |
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